Usage:
Disassemble Output Transfer Gears
start by:
a) disassemble transmission
1. Fasten a hoist to case assembly (1) with tool (A) and put the case assembly in a vertical position on blocks as shown.
2. Remove the bolts and use two 3/8"-16 NC forcing screws to remove cage (2) and shims from case assembly (1).
3. Remove the two bolts and cover (3) from cage (2). Remove the O-ring seal from the cover.
4. Use tooling (B) to remove the bearing cup from cage (2). Remove O-ring seal (4) from the cage.
5. Remove gear (5) from the case assembly.
6. Remove ring (6) from gear (5). Use tooling (C) to remove the bearing cones from gear (5).
7. Remove the bolts and locks from cage assembly (7).
8. Use two 3/8"-16 NC forcing screws and remove cage assembly (7) from case assembly (1).
9. Remove the bearing cup from cage assembly (7) with tooling (B).
10. Remove the seal rings from carrier (8).
11. Remove spring pin (9) from cage assembly (7).
NOTE: Carrier (8) will have damage after it is removed. Use a new part for replacement.
12. Remove carrier (8) from cage assembly (7).
13. Remove cover (12), the gasket, filter and screen from the case assembly.
14. Remove the bolt, washer (11), the O-ring seal and flange (10) from the case assembly.
15. Remove the bolts from cage (13). Use two 3/8"-16 NC forcing screws and remove the cage and shims from the case assembly.
16. Remove seal (14) from cage (13).
17. Remove the bearing cup from cage (13) with tooling (B). Remove O-ring seal (15) from the cage.
18. Remove spacer (16) from output shaft (17).
19. Remove the bolts from cage (18). Use two 1/2"-13 NC forcing screws and remove the cage from the case assembly.
20. Remove seal (19) from cage (18).
21. Remove the bearing cup from cage (18) with tooling (B). Remove O-ring seal (20) from the cage.
22. Remove output shaft (17) from the case assembly.
23. Use a press to push output shaft (17) out of gear (22) and bearing (21).
24. Use a press and tool (D) to remove the bearing from the other end of shaft (17).
25. Remove the bolts from shaft assembly (24).
| NOTICE |
|---|
Gear (23) is free to fall to the bottom of the case assembly when shaft assembly (24) is removed. Hold gear (23) in position when the shaft assembly is removed to prevent damage. |
26. Use two 3/8"-16 NC forcing screws to remove shaft assembly (24) from the case assembly.
27. Remove gear (23) and the inner bearing cone from the case assembly.
28. Remove spacer (25), the inner bearing cone (26) and O-ring seal (27) from shaft assembly (24).
29. Use tooling (B) to remove the bearing cups from gear (23).
30. If necessary, remove plug (28) used for the output shaft from the case assembly.
31. Remove plug (29), the O-ring seal and valve group from the case assembly. If necessary, remove the plug, spring and poppet valve from the valve body.
Assemble Output Transfer Gears
NOTE: Put clean oil on all of the parts of the output transfer gears at assembly.
1. Install poppet (2), spring (3) and plug (4) in valve body (1).
NOTE: Install plug (4) to a depth of .25 in. (6.35 mm) from the end face of valve body (1).
2. Install valve body (1) and the plug in the output transfer gear case.
3. Make a replacement of ring (7) in idler gear (5) if necessary.
4. Lower the temperature of bearing cups (6) and install them in gear (5).
5. Install O-ring seal (11), outer bearing cone (10) and spacer (8) on shaft assembly (9).
6. Install the inner bearing cone in idler gear (5). Put idler gear (5) in position in the output transfer gear case and install shaft assembly (9). Tighten the bolts that hold the shaft assembly.
7. Heat bearing cones (10) and (13) to a maximum temperature of 275°F (135°C). Install gear (11) and bearing cones (10) and (13) on output shaft (12) as shown.
NOTE: Put 7M7260 Liquid Gasket Material on the seal bore surface of cage (14) and let it dry before the seal is installed. Do not put gasket material on the seal case.
8. Use tool group (A) and install the lip type seal in cage (14) with the lip of the seal toward the inside as shown.
9. Install O-ring seal (16) on cage (14).
10. Lower the temperature of bearing cup (15) and install it in cage (14) as shown.
11. Install output shaft (12) and cage (14) in the transfer gear case. Make sure the teeth of the idler gear are engaged correctly with the teeth of the gear on output shaft (12) before the bolts that hold cage (14) are tightened.
12. Put 7M7260 Liquid Gasket Material on the seal bore surface of cage (17) and let it dry before the seal is installed. Do not put gasket material on the seal case. Use tool group (A) and install the seal in cage (17) with the lip of the seal toward the inside as shown.
13. Lower the temperature of bearing cup (18) and install it in cage (17).
14. Install O-ring seal (19) on cage (17) after the output shaft end play has been checked.
15. Install spacer (20) on the output shaft.
16. Install cage (17) and the shims on the transfer gear case.
17. Install screen (21), filter (23), the gasket and cover (22) in the transfer gear case.
18. Heat seal carrier (24) to a maximum temperature of 275°F (135°C) for no more than 10 minutes. Make sure the part number on carrier (24) can be seen and the hole in the carrier is in alignment with the hole in the cage assembly and install the carrier on cage assembly (25). Install spring pin (26) in the cage assembly.
19. Install the seal rings on carrier (24).
20. Lower the temperature of bearing cup (27) and install it in cage assembly (25).
21. Install cage assembly (25) in the output transfer gear case. Install the locks and bolts that hold the cage assembly in position.
22. Heat bearing cones (29) to a maximum temperature of 275°F (135°C). Install bearing cones (29) on each side of input gear (28).
23. Install the ring in the groove on input gear (28).
24. Install the cover and gasket on the back of cage (31).
25. Lower the temperature of bearing cup (30) and install it in cage (31).
26. Install input gear (28), the shims and cage (31) in the output transfer gear case.
NOTE: Do not install the O-ring seal on cage (31) until the input gear end play has been checked.
27. Fasten tool (B) and a hoist to the output transfer gear case. Put the case in position so that the transmission can be assembled on it.
28. Use tool group (C) and check the input gear end play. The end play must be .003 to .005 in. (0.08 to 0.13 mm). If the end play is not correct, add or subtract shims from under the rear bearing case to get the correct amount of end play.
29. Use tool group (C) and check the output shaft end play. The end play must be .003 to .005 in. (0.08 to 0.13 mm). If the end play is not correct, add or subtract shims from under cage (17) to get the correct amount of end play.
30. Make sure the O-ring seals are installed on the bearing cages after the input and output end play has been checked.
31. Install flange (32), the O-ring seal, washer and bolt on the output shaft. Tighten the bolt to a torque of 40 ± 5 lb.ft. (55 ± 7 N·m).
end by:
a) assemble transmission